Dual voltage hot swap module power control

ABSTRACT

A module hot swap circuit includes a low voltage-drop rectifier adapted to receive either positive or negative voltages of different absolute values. The rectifier is coupled to a power manager that provides dual startup/shutdown voltage thresholds and inrush current limiting. A detector prevents reverse current flow allowing the module to hold up during input voltage drop-outs.

CLAIM OF PRIORITY

This application is a Continuation of and claims the benefit of priorityunder 35 U.S.C. §120 to U.S. patent application Ser. No. 11/553,937,filed on Oct. 27, 2006, which is hereby incorporated by reference hereinin its entirety.

BACKGROUND

In many telecom and information technology applications, hot pluggablemodules are desired. A hot pluggable module is an electronic module thatprovides any number of different functions, but which can be pluggedinto a system without removing power from the system. In other words, itcan be inserted into a hot or powered receptacle that is designed tocouple the module to the system.

Modules for telecom applications may need to operate from either a +24volt or −48 volt power supply provided at the receptacle and thereforeneed to correct the polarity of the supply. They should exhibit minimumpower losses or heat dissipation, and should provide for dual voltage(24 and 48) start-up/shutdown threshold control. Such modules shouldalso provide some form of start-up delay and should control or limittheir inrush current. Further, the modules should hold up during supplydrop-out; that is, block reverse current flow.

Existing power input circuits for modules can be quite complex, yet donot provide all of these desired features.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a simplified block diagram showing functional elements of acircuit for providing hot swapping of modules for dual suppliesaccording to an example embodiment.

FIG. 2 is a circuit diagram illustrating most of the circuit of FIG. 1according to an example embodiment.

FIG. 3 is a circuit diagram of a comparator for operating with thecircuit of FIG. 2 according to an example embodiment.

FIG. 4 is a flowchart illustrating a method of accepting dual voltagesfor a hot swap module according to an example embodiment.

DETAILED DESCRIPTION

In the following description, reference is made to the accompanyingdrawings that form a part hereof, and in which is shown by way ofillustration specific embodiments which may be practiced. Theseembodiments are described in sufficient detail to enable those skilledin the art to practice the invention, and it is to be understood thatother embodiments may be utilized and that structural, logical andelectrical changes may be made without departing from the scope of thepresent invention. The following description of example embodiments is,therefore, not to be taken in a limited sense, and the scope of thepresent invention is defined by the appended claims.

FIG. 1 is a block diagram showing functional elements of a circuit 100for providing hot swapping of modules into dual supplies according to anexample embodiment. In one embodiment, the hot swap circuit includes arectifier 110 adapted to receive either positive voltage or a negativevoltages of different absolute values at input 115. A voltage sensor 120is coupled to the controller 125, which provides dual startup/shutdownvoltage thresholds and controls inrush current limiting 130, to providepower to an output 135, which is normally a DC-DC converter 155 and abulk energy storage capacitor 150. A detector 140, or comparator,detects input voltage drop-outs and shuts off the rectifier 110 toprevent reverse current flow.

In one embodiment, the rectifier comprises a FET bridge that is adaptedto receive input voltages of approximately 24 volts and −48 volts. Othervoltages may also be received in further embodiment. In one embodiment,the detector 140 shuts off the FET bridge 110 as a function of detectedreverse current flow or input voltage drop-out.

FIG. 2 is a circuit diagram illustrating the circuit of FIG. 1 accordingto an example embodiment. In one embodiment, body diodes of FETs 210-Q1,212-Q2, 214-Q3 and 216-Q4, act as a bridge rectifier to correct thepolarity of an incoming supply 220. The corrected polarity enables adownstream DC-DC converter 155 coupled to a bulkstorage capacitor 221and output lines 222, 224 to see only positive voltages. In oneembodiment, passive components around the p-FETs turn ON whichever ofFETs 214-Q3 or 216-Q4 is the correct polarity, to reduce its voltagedrop.

The bridge is coupled to a hot-swap chip 230, such as TPS2350 releasedby Texas Instruments in 2005, but other chips may be suitable, such asone provided by Maxim. The hot-swap chip 230 selects whichever supplyline to the chip (232-A or 234-B) has the higher voltage and turns onits n-FET, Q1 or Q2 (in this circuit the other line will have zerovolts) via gate A-236 and gate B-238 control lines, thereby reducing itsvoltage drop. Whichever supply line 232, 234 is higher also feedsthrough diodes D1-240 or D2-242 to a voltage threshold detect input 244of the hot-swap chip 230. In one embodiment, a diode D3-245 provides apositive voltage supply to the hot swap chip (18 to 60V).

A voltage divider network of resistors R1-246, R2-248, R3-250 and R4-252is designed such that the start-up and shut-down thresholds can be setto appropriate levels for both +24 and −48V supplies. When the inputexceeds 1.4 Vdc at pin 244 in one embodiment, the hot swap chip 230decides to turn on Q5 to power up the load. If this voltage drops by thespecified hysteresis, it will shut off Q5. Different resistor values maybe used for different desired supply levels. The resistors are alsocoupled to an over voltage pin 253 of the hot-swap chip 230.

In one embodiment, the hot-swap chip 230 senses the current through asense resistor 250 coupled between bridge FET Q1-210 and Q2-212 outputs,and the source of an inrush FET Q5-252. Current through the senseresistor 250, approximately 7 milli-ohms in one embodiment, allows thehot-swap chip 230 to adjust the n-FET 252-Q5 gate drive 251 to controlthe circuit inrush current and thereby charge up the bulk capacitor 221and start-up the downstream DC-DC converter 155.

Based on the ramp rate capacitor 256 and the sense resistor 250, thechip controls the inrush current. In continuing operation, the chip 230monitors the supply voltages and the load current continually. In theevent of a fault on the load, it will shut off Q5 via the GAT pin 251within a few microseconds. As described above, if the supply voltagedrops below the shutdown threshold at 244, the chip will shut off Q5. Ifthere is an upstream fault that drops the supply voltage, then the samething happens.

In one embodiment, a capacitor C1-254 coupled to the swap chip 230 setsa “try-again” time for fault conditions (overload-current), if needed. Acapacitor C2-256 sets a dI/dt ramp rate for the inrush (soft-start) ifneeded. A FLT pin 258 is a fault alarm output. A pin PG at 260 is apower-good signal, which could be used to enable the DC-DC converter155.

Once everything is powered up, the voltage drop between the supply 220and the DC-DC converter 155 is very low and the input losses/dissipationare minimal. If the supply voltage drops out (i.e. the voltage at 220 islower than that on capacitor 221), the current through the senseresistor will reverse. An added comparator circuit 300 in FIG. 3 willdetect the reverse current and shut off both n-FETs Q1-210 and Q2-212for a short time (a few ms), thus blocking the reverse current flow.When the supply voltage recovers, the Q1-210 or Q2-212 body diode willconduct once again, allowing power to flow into the circuit. After thecomparator 300 times out, it will once again allow the hot-swap chip toturn on Q1-210 or Q2-212, returning the system to normal operation.

In further detail, comparator circuit 300 monitors the direction of thecurrent flowing through sense resistor 250. The circuit is powered at asuitable voltage 305 derived from the supply at the RTN pin 261 of thehot-swap controller 230. Comparator 310 monitors the voltage differencebetween the Source 264 and Sense 262 pins of the controller. Resistor315 ensures that the offset voltage of the comparator will not trigger aturn off under normal DC load conditions. The output of comparator 310is coupled to gates of Q1-210 and Q2-212 through diodes so that thecomparator cannot turn on either n-FET. Timing capacitor 320 keeps thecomparator output low after the reverse current through sense resistor250 is blocked when Q1-210 and Q2-212 are off.

A method 400 of hot-swapping a telecommunications (or other) module isdescribed with respect to the flowchart in FIG. 4. Either a positive ornegative voltage of the same or different absolute value are received at410 and are rectified. Dual startup/shutdown voltage thresholds areprovided at 415 and the appropriate rectifier components are turned onat 420 to reduce their voltage drops. If the voltage level issufficient, the output is turned on and the inrush current is limited at425 as the output voltage ramps up. At 430 the DC-DC converter starts upand the module load receives its power. Once the module is in normaloperation at 435, the current flow is continually monitored at 440 todetect reverse current flow due to input voltage drop-out. In thatevent, the rectifiers are shut off at 445 to block the reverse flow. Ifthe input voltage remains low in 450, the module will shut down and thehot-swap circuit will reset at 455. If the input voltage recovers duringthe module hold-up time at 460, then the hot-swap circuit will remain onand the sequence of events will recommence at 420.

In one embodiment, receiving either positive or negative voltages ofdifferent absolute values and rectifying such received voltages isprovided by a power MOSFET bridge adapted to receive input voltages ofapproximately 24 volts and −48 volts. The FET bridge may be shut off asa function of detected reverse current flow. In a further embodiment, acontroller circuit monitors current through a sense resistor and adjustsgate drive on the inrush FET to control the inrush current, to allowstartup of a down stream DC-DC converter.

Various embodiments may have several advantages over previous circuits,such as fewer parts, reduced power loss, less room on the circuit card,and possibly less expensive. Some embodiments may also provide moreprecise inrush current limit control, and may also alloweasier-to-calculate component values and simplification of the circuitdesign. In one embodiment, it may provide faster and better-definedresponse to anomalous conditions such as voltage drop-outs, and likelymore precise and easier-to-calculate voltage thresholds. In furtherembodiment, the simpler overall and general approach can be used onother cards, or in systems with other voltage levels.

The Abstract is provided to comply with 37 C.F.R.§1.72(b) to allow thereader to quickly ascertain the nature and gist of the technicaldisclosure. The Abstract is submitted with the understanding that itwill not be used to interpret or limit the scope or meaning of theclaims.

1. A hot swap circuit, comprising: a rectifier; a controller coupled tothe rectifier and operable: to reduce a voltage drop of the rectifier;to provide a first startup/shutdown voltage threshold when a voltage ofa positive polarity is applied to the rectifier; to provide a secondstartup/shutdown voltage threshold when a voltage of a negative polarityis applied to the rectifier; and to limit inrush current; and a detectorcoupled to the rectifier and the controller and operable: to detectreverse current flow; and to shut off the rectifier in response todetection of reverse current flow.
 2. A hot swap circuit as defined inclaim 1, wherein the controller comprises a polarity sensing networkcoupled to the rectifier and operable to sense the polarity of thevoltage applied to the rectifier.
 3. A hot swap circuit as defined inclaim 2, wherein the polarity sensing network comprises a voltagedivider.
 4. A hot swap circuit as defined in claim 1, further comprisinga DC to DC converter coupled to the rectifier and operable to provide DCto DC conversion downstream of the rectifier.
 5. A hot swap circuit asdefined in claim 1, wherein the controller is further operable to turnthe rectifier back on after shutting off the rectifier in response todetection of a fault.
 6. A hot swap circuit as defined in claim 5,wherein the controller is operable to turn the rectifier back on after apredetermined delay after shutting off the rectifier in response todetection of a fault.
 7. A hot swap circuit as defined in claim 1,wherein the rectifier comprises a FET bridge.
 8. A hot swap circuit asdefined in claim 1 wherein the controller comprises a controllerintegrated circuit.
 9. A hot swap circuit as defined in claim 7, whereinthe detector comprises a sense resistance and a comparator coupled to afirst pair of FETs in the bridge.
 10. A hot swap circuit as defined inclaim 9, wherein: the controller comprises an inrush FET coupled to thesense resistance; the controller is operable to sense current throughthe sense resistance and to adjust gate drive on the inrush FET to allowstartup of a downstream DC to DC converter.
 11. A method of hot swappingan electronic module, the method comprising: applying an input voltageto a rectifier; reducing a voltage drop of the rectifier; providing afirst startup/shutdown voltage threshold when a voltage of a positivepolarity is applied to the rectifier; providing a secondstartup/shutdown voltage threshold when a voltage of a negative polarityis applied to the rectifier; limiting inrush current; monitoring therectifier for reverse current flow; and if reverse current flow isdetected, shutting off the rectifier.
 12. A method as defined in claim11, comprising sensing the polarity of the voltage applied to therectifier with a polarity sensing network.
 13. A method as defined inclaim 12, wherein the polarity sensing network comprises a voltagedivider.
 14. A method as defined in claim 11, further comprisingperforming a DC to DC converion downstream of the rectifier.
 15. Amethod as defined in claim 11, further comprising turning the rectifierback on after shutting off the rectifier in response to detection of afault.
 16. A method as defined in claim 15, wherein the step of turn therectifier back on comprises turning the rectifier back on after apredetermined delay after shutting off the rectifier in response todetection of a fault.
 17. A method as defined in claim 11, wherein therectifier comprises a FET bridge.
 18. A method as defined in claim 11wherein the controller comprises a controller integrated circuit.
 19. Amethod as defined in claim 17, wherein the detector comprises a senseresistance and a comparator coupled to a first pair of FETs in thebridge.
 20. A method as defined in claim 19, further comprising sensingcurrent through a sense resistance and adjusting gate drive on an inrushFET soupled to the sense resistance to allow startup of a downstream DCto DC converter.